This paper describes the development and application of all positional rutile flux cored wires (FCW) for welding Duplex stainless steels. Background research is presented to illustrate the key aspects of consumable development to optimise formulation to achieve both impact toughness requirements and welder friendly operability characteristics. Specifically, for 22 Cr Duplex pipework, it is shown that a minimum of 40 joules (average), 30 joules minimum individual can be achieved at –50°C in impact testing for a variety of procedures welded with Duplex FCW. Satisfactory corrosion properties are demonstrated in G48A pitting tests. The effect of heat input and interpass temperature is considered.

In terms of service application, deposition data and productivity criteria have been developed for a series of pipe sizes, thickness and welding positions to establish production benefits. Procedural data is used to verify performance on three major offshore contracts with varying specification requirements. Production experience and defect rates are analysed for contracts at the Amec Wallsend fabrication yard. Production defect rates are contrasted with that previously achieved with both the Manual Metal Arc (MMA) and Tungsten Inert Gas process (TIG).